Carpet making apparatus



May 2, 1944. H. P. was ml; 4' 2,347,816

CARPET MAKING APPARATUS Filed 001;; 28, 1940 Fla-2.

7 5 INVENTORS HAROLD P. FARIS BY JOHN E.WHITE"' A plurality of beaters engage Patented May 2, 1944 UNITED STATES PATENT OFFICE CARPET MAKING APPARATUS Harold P. Faris, Philadelphia,

White,.'lrenton, N. J., assignors Automotive Fibres, -In notation of Delaware Pa., and John E. to National Detroit, Mich, a cor- Application October 28, 1940, Serial No. 363,196

9 Claims. r01. 91-8) The present invention relates to carpet making aparatus and more particularly to apparatus for manufacturing carpet of the type disclosed in patent to Faris et a1. 2,187,140.

One of the objects of the invention is to provide efficient means for imparting vibration of different intensity at different points in the travel of the carpet as it is being made.

Another object is to provide zones of different vibration for the initial attachment and for sucl0 ceeding imbedding action of the fibers.

Another object is to provide vibration means capable of insuring the desired imbedding action of the fibers.

Other objects, advantages and novel details belt has previously been referred to and Figure 1 is a side elevation of apparatus em- 20 bodying my invention; and l Figure 2. is a diagrammatic view showing the relationship between the supporting conveyor and the beaters.

Referring first to cludes a framework for supporting a housing indicated generally at l0.

An openwork fabric to which unvulcanized blowing rubber stock is calendered may con- Figure 1 the. apparatus inveniently be provided in roll form as indicated at 15, the material 16 being withdrawn from the roll and advanced between a pair of cooperating belts l1 and I8. The material It next advances to the adhesive applicator indicated generally at H! where a uniform coating of a fluid adhesive or 5 cement is applied. The adhesive applicator may be supplied with adhesive by any suitable means, such as the elevated reservoir 91.

Within the housing ID a continuous supporting and protecting belt 20 is provided over which the calendered rubber and fabric 1'6 is advanced. the underside of the belt 20 and vibrate the same, thus transmitting the vibrations to the material It.

Fibers of predetermined length are fed downwardly to asieve (not shown) which is constantly rotated and which sifts the fibers onto the cement coated surface of the carpet material as the same is vibrated. Some of the fibers which do not adhere to the carpet or which pass endwise through the sieve mentioned are collected and are applied to the carpet at a tion of advance through a distributor 22, which includes means for breaking up balls or pills of thefibers.

p'oint further along in its direc-' A little further along in the direction of'advance of the carpet we provide a suction nozzle 23 which has an inlet opening extending across the carpet material in close proximity thereto and directly above the last of the series of beaters previously referred to. This nozzle picks up such of the fibers which are not firmly adhered to the cement, and returns them tothe system for use, as will later be described in detail.

A relatively large roll 24 is provided adjacent the exit end of the fiber applying machinefthe roll 24 preferably being covered with carding cloth so as to engage the carpet material strongly and draw the same through the machine. with a uniform tension.

Referring to Figures 1 and 2, reference is now made to the means for vibrating the carpet. The this belt may conveniently take the form of 'a canvas belting or the like. In Figure 2 in which the belt and its cooperating rolls and beaters'are shown separated from the machine, the belt 20 passes around the rolls l00,l0|, I02, I03 and I04. The rolls IM and I02 are relatively adjustable by conventional means to vary the tension in the belt 20. The beaters are arranged in a particular sequence for a particular purpose, as will now be pointed out. The beaters, which are polygonal bars rotated at relatively high speed, are arranged as follows: The beaters I05 and I06, which are the first two engaged by the ad vancing carpet fabric, are adapted to vibrate the fabric very rapidly and relatively lightly. In the specific embodiment illustrated these are shown as octagonal. The beater 101, which is the next one in the sequence, is adapted to vibrate the fabric more strongly and, accordingly, the bar is of a lesser number of sides, in the specific embodiment illustrated a square bar being employed at this point. The next beater I08 is again adapted to continue the vibration of the fabric relatively lightly and, accordingly, is provided with a greater number of sides, in the specific embodiment illustrated the beater I08 being octagonal. The following beater I09 is again adapted to vibrate the material more strongly and, accordingly, has a lesser number of sides, in the embodiment illustrated a four-sided bar being employed. The beater I I0 is again adapted to continue the vibration relatively lightly and, accordingly, a bar having a greater number of sides, as for example eight, is employed. The last two beaters HI and H2 are adapted to vibrate the material strongly and, accordingly, these heaters are bars of lesser number of sides, in the embodiment illustrated be ing square bars or rods. As seen in Figure l, the last bar H2 is'located directly beneath the suction pick up 23. Since the beater H2. is adaptedto vibrate the materialstrongly, it will loosen all of 'the fibers which are in excess of thefibers necessary to thickly cover the surface. These excessafibers are vibrated in a free condition'above. the: surface-of the fabric by thelast two beaterslll andll2. These free fibers are picked up by suction nozzle 23 and returned to the 'fiockcyclingsystemfor further use on advancing material I 6.

Itmay be stated that the precise arrangement of thebeatersineed' notbefollowed, but it is desirable that the beating be carried out at dif-. ferentintensitiesr It isimportant that the initial vibration bevery rapid and relatively light. At this-time the freshly cut-fibers are being sifted onto the fabric and'the rapid, light vibration tends to ma relatively large number of these fibers onend. Asthematerial advances a short distance his then desirable to vibrate the same much more strongly. This will serveto drive the fibers into the adhesive, and in some cases it is found that some-of the fibers are driven completely through the adhesive and into the upper surface of the sponge rubber stock.

Referring to Figure 2, it will be noted that the zone of firstapplication is indicated generally by the bracket H5, and throughout this zone the fabric is being vibrated very rapidly and relatively lightly. In the second zone indicated by the bracket lit, no fiberis being applied, and the fabric in this zone is vibrated strongly and less rapidly. The third zone of fiber application is indicated by the bracket I l1, and again in thiszone the material is vibrated very rapidly. Following this, in the zone H8, the carpet is vibrated strongly so. as to cause the fibers to be deeply embedded into thecement. In the next succeeding zone indicatedby bracket H9 the material is vibrated lightly to give an'opportunity for loose unattached fibers to become attached endwise in the cement. In the final zone indicated by the bracket I20, the material is strongly vibrated for the purpose of deeply embedding all of the fibers,

including those which have become attached in the zone H9 and also to cause such fibers as remain unattached to be vibrated free of the surface. of the carpet in position to be picked up by the suction nozzle". It is found that the particular arrangement described substantially improves theresult obtainedand while the particu lar number of sides of the vibrating elements, and the fact the precise arrangement may be somewhat. modified, it is desirable to follow the teachings'herein setforth, at least to the extent of providing zones of differential vibration for the initial attachment andsucceeding embedding of the fibers.

What weclaim as our invention is:

1. A machine for making a'cemented pile carpet havingmeans for advancing adhesively coated sheet material in a predetermined direction, means above saidadvancing means for depositing cut fibers onto the adhesive coating of the material as the latter is advanced, and means beneaththe advancing means at a series of separate points thereof/for successively vibrating at diilerentintensities the adhesively coated sheet material as it is advanced, said vibrating means including a series of spaced rotating beater bars engageable with theunderside of the advancing means, the first two bars of the series being tagonal in cross section, the next four succeeding bars of-the series being alternately. substantially square shape and octagonal in cross section, and the last two barsof the series being square shape in cross section.

2. A: machine for making a cemented pile carpet having meansforadvancing adhesively coated sheet material in a predetermined direction,

means above said advancingmeans for depositing cut fibers. onto the adhesive coating of the material as the latter is advanced, and means beneath the advancing means at a series of separate points thereof "for successively vibrating at different intensities the adhesively coated sheet material, saidvibrating means including a series of spaced rotating beater bars engageable with the-underside of the advancing means, some of said bars being octagonal in cross section and somebeingsquare-shape in cross section.

3. In a machine having means for advancing in a predetermined direction sheet material having an adhesive coating, and means above said advancing means for depositing cut fibers onto the adhesive coating of the material asthe latter is advanced; means beneath the advancing means at a series of separate points thereof for successively vibrating at diflerent intensities the adhesively coated sheet material, said vibrating means including spaced beater elements engageable with the underside of the advancing means, some of said elements being rapidly rotating polygonal members, and some of said elements being relatively slowly rotating four sided memhers. I 4. In a machine having'means for advancing in a predetermined direction sheet material having an adhesive coating, and means above said advancing means for depositing cut fibers onto the adhesive coating of the material as the latter is advanced; means beneath the advancing means at a series of separate points thereof for successively vibrating at different intensities the adhesively coated sheet material, said vibrating meansincluding spaced beater elements engageable with the underside of the advancing means, some of said elementsbeing rotatable octagonal members, and some of said elements being rotatable members having fewer beater sides.

5. In a machine having means for advancin in a predetermined direction sheet material having an'adhesive-coating, and means above theadvancing means for depositing cut fibers onto the adhesive coating as the material is advanced; means beneath the advancing means at a series of separate points thereof for successively vibratingat difierent intensities the adhesively coated sheet material as it isadvanced, said vibrating means including beaters ofdiiferent cross sectional configuration arranged so that the vibration at the first point of the series is vry rapid and relatively light to place a relatively large number of the deposited fibers on end at the surface of the adhesive coating, thevibration at the next point of the series being less rapid but sufficiently strong to drive the deposited fibers on end into the adhesive coating. and the vibration at succeeding points to the last point of the series being alternately rapid and light and less rapid and strong so that any loose fibers will be imbedded endwise into the adhesive coating, and all fibers lmbedded endwise into the adhesive coating will be lmbedded more deeply into said adhesive coating;

6. In a, machine having means for advancing in. a predetermined direction sheet material having an adhesive coating, and means above the ading an adhesive coating,

vancing means for depositing out fibers onto the adhesive coating as the material is advanced; means beneath the advancing means at a series of separate points thereof for successively vibrating at different intensities the adhesively coated sheet material as it is advanced, said vibrating means including spaced beater elements of difierent cross sectional configuration arranged in a predetermined sequence and engageable with the underside of the advancing means, the first two beater elements 0! the series being octagonal in cross section, the next four succeeding beater elements of the series being alternately substantially square shape and octagonal in cross section, and the last two beater elements of the series being square shape in cross section.

I. In a machine having means for advancing in a predetermined direction sheet material havand means above the advancing means for depositing cut fibers onto the adhesive coating as the material is advanced; means beneath the advancing means at a series of separate points thereof for successively vibrating at different intensities the adhesively coated sheet material as it is advanced, said vibrating means including a series of spaced beater elements arranged in a predetermined sequence and engageable with the underside oi the advancin means, some of said beaterelements being octagonal in cross section, the other of said beater elements being substantially square shape in cross section.

8. In a machine having means for advancing in a predetermined direction sheet material hav= ing an adhesive coating, and means above the advancing means for depositing cut fibers onto the means at a series of separate adhesive coating as the material is advanced; means including beater bars oi diflerent cross sectional configuration beneath the advancing points thereof for successively vibrating at diiierent intensities the adhesively coated sheet material so that the deposited fibers will be placed on end at the surface of the adhesive coating and then will be imbedded 'endwise into said adhesive coating.

9. In a machine having means for advancing in a predetermined direction sheet material having an adhesive coating, and means above said advancing means for depositing cut fibers onto the adhesive coating of the material as the latter is advanced; means beneath the advancing means at a series of separate points thereof for succesat different intensities the adhesively coated sheet material as it is advanced, said vibrating means including rotatable beater bars of diflerent cross sectional configuration arranged so that the vibration at the first point of the series is very rapid and relatively light to place a relatively large number of the sifted fibers on end at the surface of the adhesive coating, the vibration at the next point of the series being less rapid but sumciently strong to drive the fibers on end into the adhesive coating, and the vibration at succeeding points to the last point oi the series being alternately rapid and light and less rapid and strong so that any loose fibers will be imbedded into the adhesive coating and all fibers imbedded endwise into the adhesive coating will be imbedded more deeply into said adhesive coating.

HAROLD P. FARIS. JOHN E. WHITE. 

